CN102903833B - Wide angle based indoor lighting lamp - Google Patents

Abstract

The present invention provides an embodiment of a lighting structure. The lighting structure includes a light emitting diode (LED) device on a substrate; a lens fixed on the substrate and over the LED device; and a diffuser cover fixed on the substrate and covering the lens, wherein the lens and the diffuser cover are designed and configured to redistribute emitted light from the LED devices for wide-angle illumination. The invention also provides a wide-angle indoor lighting lamp.

Description

Wide Angle Interior Lighting

technical field

The invention relates to the field of semiconductors, and more specifically, the invention relates to a wide-angle indoor lighting lamp.

Background technique

Light emitting diodes (LEDs) are used in a wide variety of applications including indicators, light sensors, traffic lights, broadband data transmission, and lighting applications. In particular, LEDs are more suitable for lighting applications due to their low power consumption and long service life. In lighting applications, LEDs have some limitations, such as a narrow band spectrum. The narrow spectrum limitation of this band can be overcome by integrating various types of LEDs, thus providing white light. Another limitation is directed radiation. Radiant optical power from LEDs is typically distributed over a small solid angle, which provides a narrow viewing angle and differs from eye lighting. Such directional lighting and bright light are uncomfortable and painful to the human eye. The narrow viewing angle of LED lighting is not required, especially in interior lighting functions, unless lighting in a specific direction is required for a specific application. Current indoor LED lights use Lambertian emitters and diffusers to distribute the emitted light. However, these techniques for distributing light can only achieve 140 degrees of illumination with some backlighting. Therefore, the radiation of the LED is still directional and cannot form a uniform light distribution pattern. Accordingly, there is a need for configurations and methods of LED structures to address the above-mentioned problems.

Contents of the invention

In order to solve the problems existing in the prior art, according to one aspect of the present invention, a lighting structure is provided, comprising: a light emitting diode (LED) device located on a substrate; a lens fixed on the substrate, and located above the LED device; and a diffuser cover fixed on the substrate and covering the lens, wherein the lens and the diffuser cover are designed and configured to absorb light from the LED The emitted light from the device is redistributed for wide-angle illumination.

In the lighting structure, the lens includes an inner surface and an outer surface; the inner surface includes a first side and a first top; the outer surface includes a second side and a second top; and the first side portion, the first top portion, the second side portion, and the second top portion are designed and configured to redistribute light emitted from the LED device into a solid angle greater than 2π steradians.

In the lighting structure, the first side, the first top, the second side, and the second top are designed and configured such that the emitted light is Including: a first light beam, passing through said first top and said second top, is assigned a first solid angle between 0 steradians and about 2π*[1-cos(π/4)] steradians Inside; a second light beam, passing through said first side and said second side, is distributed between about 2π*[1-cos(π/4)] steradian and about 2π*[1-cos(100π /180)] within the second solid angle between steradians; and a third beam, passing through the first top, reflected from the second top, and passing through the second side, is distributed Within the third solid angle between about 2π*[1-cos(100π/180)] steradians and 4π steradians.

In this lighting structure, the second top has a recess.

In the lighting structure, the second top includes a center and an edge surrounding the center; the second top is spaced apart from the substrate along a first direction, thereby defining a boundary along the first direction. The height H from the edge of the second top to the top surface of the substrate; the second top spans from the center to the edge along a second direction perpendicular to the first direction, thereby defining a first radius r; the recess includes a recess depth d defined as a distance from the edge to the center along the first direction; and a range of a first ratio d/H Between about 0.5 and about 0.8.

In the lighting structure, the second side defines a circular area on the substrate, and the circular area has a second radius R along the second direction; and a second ratio r/R ranges between about 0.3 and about 1.0.

In the lighting structure, the first top is spaced apart from the substrate along the first direction, thereby defining a height h of the first top to the top surface of the substrate; and a third ratio The range of h/H is between about 0.1 and about 0.4.

In the lighting structure, it further includes: a second lens covering the first lens and disposed inside the diffusion cover.

In the lighting structure, the substrate includes a mechanical base.

In this lighting structure, the mechanical base contains thermally conductive material and is designed as a heat sink.

In the lighting structure, the mechanical base includes a first part adjacent to the LED device and a second part away from the LED device; the first part and the second part are arranged along a first direction; the first part A portion has a first size along a second direction perpendicular to the first direction; the second portion has a second size along the second direction; and the second size is greater than the first size.

In the lighting structure, it further includes: a heat dissipation circuit board electrically connected to the LED device and arranged between the LED device and the substrate.

According to another aspect of the present invention, a lighting structure is provided, including: a light emitting diode (LED) device configured on a substrate; a first lens fixed on the substrate and covering the LED a device; and a second lens mounted on the substrate and covering the first lens, wherein the first lens and the second lens are shaped and configured to align with the LED device The emitted light is redistributed for wide-angle lighting.

In this lighting structure, the first lens includes a first inner surface facing the LED device and a first outer surface facing away from the LED device; the second lens includes a second inner surface facing the LED device surface and a second outer surface facing away from the LED device; and each of the first inner surface, the first outer surface, the second inner surface, and the second outer surface is designed to have a portion selected from a hemisphere, a half The group of parts of an ellipse and a surface that has a top and sides with recesses.

In the lighting structure, each of the first lens and the second lens comprises a transparent material selected from polycarbonate (PC) and polymethyl methacrylate (PMMA). group.

In the lighting structure, the second lens further includes diffusion particles dispersed in the transparent material to obtain a light diffusion effect.

In this lighting structure, the LED device includes a plurality of LED chips arranged on the substrate.

In the lighting structure, the first lens is shaped to have a batwing structure.

In the lighting structure, it further includes: a third lens stacked with the first lens and the second lens to further redistribute the light emitted from the LED device.

According to yet another aspect of the present invention, there is provided a method of manufacturing a lighting structure, comprising: attaching a light emitting diode (LED) device to a substrate; attaching a first lens to the substrate such that the first A lens overlies the LED device; and attaching a second lens to the substrate such that the second lens overlies the first lens.

In the method, further comprising: prior to attaching the first lens to the substrate, forming a first lens, the first lens shaped to redistribute emitted light from the LED device , to create wide-angle lighting.

In the method, said forming the first lens includes using a technique selected from the group consisting of injection molding and extrusion molding.

Description of drawings

The present invention is better understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the number and size of the various components may be arbitrarily increased or decreased for clarity of discussion.

Figure 1 is a cross-sectional view of a lighting structure constructed in accordance with one or more embodiments;

2 and 3 are top views of light emitting diode (LED) devices constructed in accordance with various embodiments and integrated in the lighting structure of FIG. 1;

FIG. 4 is a top view of the heat sink of the lighting structure of FIG. 1 constructed in accordance with various aspects of the present invention in one embodiment;

5 to 8 and 12 are cross-sectional views of lighting structures constructed according to various embodiments;

Figure 5a is a top view of a lens in the lighting structure of Figure 5 constructed according to one embodiment; and

9 to 11 are cross-sectional views of lens surface shapes in the lighting structure of FIG. 8 according to various embodiments.

Detailed ways

It can be understood that the following disclosure provides a variety of different embodiments or examples for realizing different features of each embodiment. Specific examples of components and arrangements are described below to simplify the present disclosure. Of course, these are only examples and are not intended to limit the invention. The present invention may repeat reference symbols and/or characters in various instances. This repetition is for simplicity and clarity, and does not in itself indicate a relationship between the various embodiments and/or configurations described.

FIG. 1 is a cross-sectional view of a lighting structure 100 . 2 and 3 are top views of light emitting diode (LED) devices integrated in lighting structure 100 constructed according to various embodiments. FIG. 4 is a top view of a heat sink of a lighting structure 100 constructed in accordance with various aspects of the present invention in one embodiment. Referring to FIGS. 1 to 4 , a lighting structure 100 and a method of manufacturing the same are collectively described. The lighting structure 100 includes an LED device 102 as a light emitting source. The LED device 102 is connected to a circuit board 112 and further attached to a substrate 114 .

The LED device 102 includes one chip 104 as shown in FIG. 2 , or a plurality of LED chips 104 as shown in FIG. 3 . When the LED device 102 includes a plurality of LED chips 104, in order to obtain a desired lighting effect, the plurality of LED chips can be arranged in an appropriate array. For example, multiple LED chips 104 are configured such that common illumination from individual LED chips facilitates enhanced uniformity of illumination of emitted light over large angles. In another example, the plurality of LED chips 104 includes individual LED chips 104 each designed to provide a different wavelength or spectrum of visible light, such as a first subset of LED chips for blue, while a second subset of LED chips is used for red. In this case, the individual LED chips 104 collectively provide white lighting or other lighting effects according to specific applications. In various embodiments, each LED chip 104 includes a light emitting diode or a plurality of light emitting diodes. As an example, when the LED chip includes a plurality of light emitting diodes, for high voltage operation, these diodes are electrically connected in series, or further electrically connected in parallel in series connected diode groups, thereby providing redundancy and device robustness .

As an example, the LED chip 104 in the LED device 102 is further described below. The LED chip 104 includes a semiconductor p-n junction that can emit spontaneous radiation in the ultraviolet, visible or infrared regions of the electromagnetic spectrum. In one embodiment, the LED emits blue light. The LED chip 104 is formed on a growth substrate, such as a sapphire, silicon carbide, gallium nitride (GaN), or silicon substrate. In one embodiment, the LED chip 104 includes a cladding layer doped with n-type impurities and a cladding layer doped with p-type impurities, and the cladding layer is formed on the n-type doped cladding layer. above. In one example, the n-type cladding layer includes n-type gallium nitride (n-GaN), and the p-type cladding layer includes p-type gallium nitride (p-GaN). Alternatively, the cladding layer may contain GaAsP, GaPN, AlInGaAs, GaAsPN or AlGaAs doped in a corresponding type. LED chip 104 further includes a multiple quantum well (MQW) layer disposed between n-GaN and p-GaN. The MQW structure includes two alternating semiconductor layers, such as Indium Gallium Nitride/Gallium Nitride (InGaN/GaN), and is designed to tune the radiation spectrum of the LED device. The LED chip 104 further includes electrodes, which are respectively electrically connected to the cladding layer doped with n-type impurities and the cladding layer doped with p-type impurities. For example, a transparent conductive layer, such as indium tin oxide (ITO), may be formed on the cladding layer doped with n-type impurities. An n-electrode is formed and connected to the cladding layer doped with n-type impurities. In a modification of this embodiment, lead interconnects may be used to connect the electrodes to the terminals on the carrier substrate. The LED chip 104 can be attached to the carrier substrate by various conductive materials such as silver paste, solder or metal bonding. In another embodiment, other techniques such as through silicon vias (TSVs) and/or metal traces may be used to connect the light emitting diodes to the carrier substrate.

In another embodiment, phosphors are used to convert the emitted light to different wavelengths of light, which can be combined with the emitted light to produce a broader spectrum of light, such as white light. The scope of the embodiments is neither limited to any particular type of LED nor to any particular color scheme. In the described embodiments, one or more phosphors are disposed around the light emitting diodes in order to vary and change the wavelength of emitted light, such as from ultraviolet (UV) to blue or from blue to red. The phosphor is usually powdered and contained in other materials such as epoxy or silicone (also known as phosphor glue). The phosphor paste is applied to the LED chips 104 using appropriate techniques and further shaped into the appropriate shape and size.

Various embodiments may use any type of LED suitable for the application. For example, conventional LEDs such as semiconductor-based LEDs, organic LEDs (PLEDs), polymer LEDs (PLEDs), etc. may be used. In high output power LEDs, various embodiments may be used in a specific manner to ensure that their light output is similar to that expected from an incandescent bulb.

The LED chip 140 is further connected to the circuit board 112 to provide electric power and control the LED chip 104 . The circuit board 112 may be part of a carrier substrate. If multiple LED chips 104 are used, then the LED chips 104 can share a circuit board. In this embodiment, the circuit board 112 is a heat-dissipating circuit board 112 for efficient heat dissipation as well as for heat dissipation. In one example, a metal core printed circuit board (MCPCB) is used. MCPCB can be applied to a variety of designs. Exemplary MCPCBs used include PCBs, wherein the base material of the PCB includes metals, such as aluminum, copper, copper alloys, and the like. The thermally conductive medium layer is disposed on the base metal layer, thereby electrically isolating the circuit on the printed circuit board from the underlying base metal layer. An LED chip 104 and its associated traces may be disposed over the thermally conductive dielectric material.

During normal operation, LED chips 104 generate heat and light. The buildup of heat may damage the LED chip 104 and/or reduce the light output of the LED chip 104 over time. MCPCB can effectively remove heat from LED chips. Specifically, in one example, the heat in the LED chip 104 is transferred to the metal base through a thermally conductive dielectric layer. The metal base then conducts the heat to the heat sink, which dissipates the heat into the ambient atmosphere. In other words, the thermally conductive dielectric layer and the metal base act as a thermal bridge to transfer heat effectively and efficiently from the LED to the heat sink.

In some instances, the metal base directly contacts the heat sink, while in other instances an intermediate material is used between the heat sink and circuit board 112 . The intermediate material may include, for example, double-sided thermal tape, thermal glue, thermal grease, or the like. Various embodiments may be adapted to use other types of MCPCBs. For example, some MCPCBs include multiple wiring layers, and such MCPCBs may be used where appropriate. The circuit board may be made of materials other than those described above. In fact, suitable materials can be used, even materials with lower thermal conductivity than those used in MCPCBs. For example, other embodiments may use circuit boards made from FR-4, ceramic, and the like.

In another example, the circuit board 112 may further include a power conversion module. Electric power for indoor lighting is usually provided by alternating current (ac) such as 120V/60Hz in the United States and 200V and over 50Hz in most of Europe and Asia, and incandescent lamps usually apply power directly to the bulb on the filament. The LED device 102 requires a power conversion module to change the common room voltage/frequency (high voltage AC) to power suitable for the LED device 102 (DC). Various embodiments may apply any desired type of power to the LED array to achieve any desired lighting effect.

Substrate 114 is a mechanical base for providing mechanical support for LED device 102 . Substrate 114 includes a metal, such as aluminum, copper, or other suitable metal. Substrate 114 may be formed by a suitable technique such as extrusion molding or die casting. Substrate 114 , or at least a portion of substrate 114 , also acts as a heat sink (hence also referred to as heat sink 114 ). In one embodiment, the heat sink 114 is designed to have a top 114a having a first dimension to avoid shielding the backward light emitted in the LED device 102 and a bottom 114b having a second dimension greater than the first dimension. size, thus providing efficient heat dissipation. The first part and the second part are connected or formed as one part with a desired thermal conductivity. The first portion 114 a of the heat sink 114 is designed to fix the LED device 104 and the circuit board 112 .

According to another embodiment, in order to accomplish thermal management while providing a satisfactory light pattern, the heat sink 114 has multiple faces, each face having a length dimension parallel to the length dimension of the lamp itself (in FIG. 1 Also referred to as the first direction or the z direction). These faces are important to the apparent bulb form factor and surface.

To enhance heat transfer, heat sink 114 has fins. In a particular example, the second portion 114b has fins as shown in FIG. 4 . Each fin is positioned between two adjoining faces and projects outwardly from the central axis of the lamp. These fins have a substantial surface area exposed to the ambient atmosphere, thereby facilitating heat transfer from the center of the lamp to the air. The spacing between the fins provides a configuration such that emitted backward light (with a solid angle greater than 2π steradians) can pass through substantially unobstructed.

The lighting structure 100 includes a lens 122 configured to be positioned around the LED device 102 . Lens 122 includes an inner surface 124 and an outer surface 126 . Inner surface 124 and outer surface 126 are shaped and sized accordingly to efficiently distribute emitted light from LED device 102 into a wide angle. In one example, the outer surface 126 of the lens 122 is designed to include a recess such that the outer surface 126 slopes downward toward the center. More specifically, the central portion of the outer surface of the lens 122 is lower than the edges when measured along the first direction (z direction).

Lens 122 comprises a material that is substantially transparent to emitted light from the LED device. In one example, the transmittance of emitted light from LED device 102 is greater than about 90%. In various embodiments, lens 122 comprises polymethyl methacrylate (PMMA), polycarbonate (PC), or other suitable materials. Lens 122 may be formed by any suitable technique, such as injection molding or extrusion molding. With proper design and configuration of lens 122, light emitted from LED device 102 can be distributed over a solid angle of more than 2π*[1-cos(100π/180)] steradians. A second lens or lenses may be integrated into the lighting structure 100 to further enhance wide angle lighting. Various embodiments of the lighting structure 100 are described below. These examples are provided to illustrate the present invention, not to limit the scope of the present invention.

FIG. 5 provides a cross-sectional view of a lighting structure 100 (parts shown for simplicity) constructed in accordance with various aspects in one embodiment. The lighting structure 100 includes a lens 122 having an inner surface 124 and an outer surface 126 . In one embodiment, the inner surface 124 has a first side (or inner side) 124a and a first top (or inner top) 124b. The outer surface 126 includes a second side (or outer surface) 126b and a second top surface (or outer top surface) 126b.

The first lens 122 is designed to efficiently distribute the emitted light originating from the LED device 102 into an apex angle greater than 100 degrees or a solid angle of 2π*[1-cos(100π/180)] steradians. In one embodiment, inner surface 124 is designed to have an angle defined from LED device 102 to an edge (or rim) where inner side surface 124a meets inner top surface 124b. In this embodiment, the defined angular range is between approximately 70 and 90 degrees. In another embodiment, the inner top surface 124b includes a geometric structure such as a flat, concave, or convex surface. In yet another embodiment, the outer side 126a includes a geometric structure such as a flat, concave, or convex surface. In yet another embodiment, the outer top surface 126b includes a geometric structure such as a flat, concave, or convex surface.

The inner top surface 124b is spaced apart from the substrate 114 along a first direction (z-direction) to define a first height h relative to the substrate 114 as shown in FIG. 5 . FIG. 5 a shows a top view of part of the lens 122 in the lighting structure 100 . Specifically, only the outer surface 126 (126a and 126b) of lens 122 is shown in FIG. 5a. With reference to Figures 5 and 5a, the outer surface 126 is further described. As shown in Figure 5a, the outer top surface 126b includes a center (labeled "Center") and an edge (or first edge and labeled "Edge 1") in a top view. The outer top surface 126b spans from the center to the edge along a second direction, thereby defining a first radius "r1. As shown in Fig. 5, this second direction is perpendicular to the first direction and is also referred to as r Direction. Outer side 126a defines a circular area on substrate 114 and the circular area has a second radius R along the second direction. Particularly, outer side 126a is in contact with outer top surface 126a at a first edge Contacts and contacts the substrate 114 at a second edge (labeled "Edge 2"). The second radius R is defined along a second direction from the center to the second edge.

Similarly, inner top surface 126a also includes a center. A virtual line is defined along the first direction and passes through the center of the inner top surface 126a and the center of the outer top surface 126b. In FIG. 5, this dotted line is called the main axis.

The outer top surface 126b is spaced apart from the substrate 114 along a first direction (z-direction), thereby defining a second height H between the first edge and the substrate 114 . In this embodiment, the outer top surface 126b includes a concave portion such that the first edge is higher than the center of the outer top surface 126b. The outer top surface 126b is sloped such that it gets closer to the substrate 102 as it approaches the center from the first edge. As shown in FIG. 5 , the concave portion of the outer top surface 126 b can be measured by a parameter d, which is defined as the distance between the center of the outer top surface and the first edge of the outer top surface along a first direction.

In one embodiment, inner surface 124 and outer surface 126 are designed to efficiently redistribute emitted light using a redistribution mechanism, which will be further described below with reference to FIG. 6 . In order to realize the redistribution mechanism, according to various examples, the lens 122 is designed such that the dimensions defined above have ratios to each other. In one example, the first ratio is determined as r/R and the first ratio r/R ranges between about 0.3 and about 1.0. In another example, the second ratio is determined as d/H and the second ratio d/H ranges between about 0.5 and about 0.8. In another example, the third ratio is defined as h/H and the third ratio h/H ranges between about 0.1 and about 0.4.

The lighting structure 100 with lens 122 in FIG. 5 is further explained with reference to FIG. 6 for a redistribution mechanism, according to one or more embodiments. During operation of the lighting structure 100, the LED devices 102 emit light. The emitted light is distributed into a cone with an apex angle of 90 degrees or less. The apex angle is measured with reference to the main axis shown in FIG. 6 . The corresponding solid angle is 2π steradians or less. The emitted light passes through lens 122 and is redistributed by various surfaces of lens 122 , including inner side 124a, inner top 124b, outer side 126b, and outer top 126b. As described as an example for purposes of explanation, emitted light from LED device 102 includes a first beam (labeled "beam a"), a second beam (labeled "beam b"), and a third beam (labeled "beam b"). labeled "beam c"). As shown in FIG. 6, the first light beam is initially directed into the solid corner such that the light beam passes through the inner top surface 124b and then through the outer top surface 126b. The first light beam is redirected into an apex angle between 0 degrees and about 45 degrees. The corresponding solid angles range from 0 steradian to approximately 2π*[1-cos(π/4)] steradian. As shown in FIG. 6, the second light beam is initially directed into the solid corner such that the light beam passes through inner side 124a and then through outer side 126a. The second light beam is redirected into an apex angle between about 45 degrees and about 100 degrees. The corresponding solid angle ranges between about 2π*[1-cos(π/4)] steradians and about 2π*[1-cos(100π/180)] steradians. As shown in FIG. 6, the third light beam is initially directed into the cube corner such that the light beam passes through the inner top surface 124b, reflects at the outer top surface 126b, and passes through the outer side 126a. The third light beam is redirected into an apex angle between approximately 100 and 180 degrees. The corresponding solid angles range between about 2π*[1-cos(100π/180)] steradians and 4π steradians. Thus, emitted light from LED device 102 is redistributed into a wide angle by lens 122 with engineered inner surface 124 and outer surface 126 . In the example, emitted light from LED devices 102 is redistributed into a full solid angle from 0 to 4π steradians.

Figure 7 provides a cross-sectional view of a lighting structure 100 (only partially shown for simplicity) constructed in accordance with various aspects in another embodiment. The lighting structure 100 of FIG. 7 is similar to the lighting structure 100 of FIG. 5 , but it further includes a diffuser cover 128 . In one embodiment, the diffuser cover 128 is secured to the top 114a of the substrate 114 . For uniform illumination, the diffuser cover 128 is designed with suitable materials to diffuse the emitted light from the LED devices 102 . In particular, light redistributed from lens 122 is diffused by diffuser cap 128 . In one embodiment, the diffuser cover 128 comprises a transparent material, such as PC, PMMA, or other suitable material. The diffuser cover may be formed by suitable techniques such as injection molding or blow moulding. In order to obtain a light diffusion effect, the diffusion cover 128 further includes diffusion particles dispersed in the transparent material. The size and concentration of the diffusing particles are designed to effectively diffuse the emitted light.

Through the lens 122 and the diffuser cover 128 integrated in the lighting structure 100, the emitted light from the LED devices 102 is more evenly redistributed into a wide angle. In one example, the light uniformity in the solid angle region between 0 and about 2π*[1-cos(135π/180)] steradians is less than about 20%. Light uniformity is defined as a percentage such that the intensity of illumination at any angle in the solid angle region (in the example described, between 0 and 2π*[1-cos(135π/180)] steradians) is equal to the overall The difference between the average intensities of the angular regions should not be greater than the above mentioned percentages. In the example described, this percentage is 20%. In a particular example, light uniformity can be formulated as |II _ave |/I _ave . In this formula, the parameter I is the intensity of illumination at any angle in a defined angular region. The parameter I _ave is defined as the average illumination intensity over a defined angular area. In the above example, the light uniformity is |II _ave |/I _ave ≤20%. In a modification of this example, the light uniformity for the backward light is |II _ave |/I _ave ≦5%. In this example, backward light is defined as light redistributed from the LED device 102 within a solid angle between approximately 2π*[1-cos(135π/180)] steradians and 4π steradians.

Figure 8 provides a cross-sectional view of a lighting structure 130 (only partially shown for simplicity) constructed in accordance with various aspects in another embodiment. The lighting structure 130 of FIG. 8 is similar to the lighting structure 100 of FIG. 5 with respect to other components such as the LED device 102 , the circuit board 112 and the substrate 114 . However, the lighting structure 130 includes a first lens 122 that is configured to surround the LED device 102 and a second lens 132 that surrounds the first lens 122 . The first lens 122 includes a first inner surface 124 and a first outer surface 126 . The second lens 132 includes a second inner surface 134 and a second outer surface 136 . The respective surfaces of first lens 122 and second lens 132 are designed to efficiently redistribute emitted light from LED device 102 into a wide angle (such as >2π*[1-cos(100π/180)] steradians). In one embodiment, each of the surfaces of the first lens 122 and the second lens 132 (including the first inner surface 124, the first outer surface 126, the second inner surface 134, and the second outer surface 136) are each is designed to have a corresponding shape and size such that light emitted from the LED device 102 and passed through the first and second lenses is efficiently redistributed into a wide angle. In particular, second inner surface 134 and second outer surface 136 of second lens 132 are designed and configured to refract emitted light backwards (into a solid angle greater than 2π steradians).

In one embodiment, each of the surfaces of the first lens 122 and the second lens 132 (including the first inner surface 124, the first outer surface 126, the second inner surface 134, and the second outer surface 136) are each Designed to have a shape selected from the group consisting of hemispheres (as shown in Figure 9), semi-ellipses (as shown in Figure 10), and surfaces with recessed tops and sides (as shown in Figure 11) The corresponding geometry of the group. 9-11 are cross-sectional views of surface geometries constructed in accordance with various aspects in one or more embodiments. In particular, the surface geometry in Figure 11 drops one height from the center. In a particular embodiment, at least one of these surfaces ( 124 , 126 , 134 , and 136 ) is shaped to have a top and sides with recesses as shown in FIG. 11 .

The second lens 132 spans a first dimension along a first direction (z direction) and spans a second dimension along a second direction (r direction). In one embodiment, the first dimension ranges between about 20mm and about 40mm. In another embodiment, the second dimension ranges between about 30mm and about 60mm.

At least one of the first lens 122 and the second lens 132 includes a highly transparent material, such as a material having a transmittance greater than about 90%. In one embodiment, the highly transparent material includes glass or a polymeric material. In various embodiments, the highly transparent material comprises PMMA or PC formed by a suitable technique, such as injection molding. In another embodiment, the second lens 132 includes a diffuser-like material with high transmittance. For example, the second lens 132 includes a material having a transmittance greater than about 90% and a cloudiness greater than about 80%. In one example, in order to obtain light diffusion effect, the second lens 132 includes a transparent material (such as PC or PMMA) dispersed with diffusion particles.

In an optional embodiment, the lighting structure 130 further includes a third lens or more lenses to efficiently redistribute the emitted light from the LED devices 102 into a wide angle with high angular uniformity.

Figure 12 provides a cross-sectional view of a lighting structure 140 (only partially shown for simplicity) constructed in accordance with various aspects in another embodiment. The lighting structure 140 of FIG. 12 is similar to the lighting structure 130 of FIG. 8 , but further includes a diffuser cover 128 . The lighting structure 140 specifically includes a first lens 122 and a second lens 132 formed using one or more transparent materials. In one embodiment, the lighting structure 140 further includes a diffuser cover 128 secured to the top 114 a of the substrate 114 . For uniform illumination at different angles, the diffuser cover 128 is designed with suitable materials for diffusing the emitted light from the LED devices 102 . In particular, the redistributed light from the first lens 122 and the second lens 132 is further diffused by the diffuser cover 128 . In one embodiment, the diffuser cover 128 comprises a transparent material, such as PC, PMMA, or other suitable material. Diffuser cover 128 may be formed by suitable techniques such as injection molding or plastic blow. In order to obtain light diffusion effect, the diffusion cover 128 further includes diffusion particles dispersed in the transparent material.

While a number of embodiments have been provided and illustrated in this disclosure. However, other alternatives and embodiments may also be used without departing from the spirit of the invention. In one embodiment, the respective surfaces of the first lens 122 and/or the second lens 132 may be designed with different geometric structures for desired light redistribution. In another embodiment, lens 122 (and/or lens 132 ) has a batwing configuration. Batwing lenses have prismatic ribs for refracting the light path. In particular, one of the faces (124, 126, 134 and 136) has a batwing structure. In one example of a lens surface with a batwing structure, the lens surface is similar to the geometry in FIG. 11 , but the lens surface includes peaks and depressions such as, for example, a wave-like surface profile in cross-section.

Accordingly, the present invention provides lighting structures. The lighting structure includes a light emitting diode (LED) device on a substrate; a lens fixed on the substrate and over the LED device; and a diffuser cover fixed on the substrate and covering the lens, wherein the lens and a diffuser cover designed and configured to redistribute emitted light from the LED devices for wide-angle illumination.

In one embodiment, the lens includes an inner surface and an outer surface; the inner surface includes a first side and a first top; the outer surface includes a second side and a second top; and the first side, the first top, The second side and the second top are designed and configured to redistribute emitted light from the LED device into a solid angle greater than 2π steradians.

In another embodiment, the first side, the first top, the second side and the second top are designed and configured such that the emitted light comprises the first light beam, the second light beam and the third light beam during operation of the lighting structure. Beams, the first beam passing through the first top and the second top, are distributed within a first solid angle between 0 steradian and about 2π*[1-cos(π/4)] steradian; the second beam passing through Through the first side and the second side, the second side is assigned between about 2π*[1-cos(π/4)] steradian and about 2π*[1-cos(100π/180)] steradian Within the solid angle; the third beam passes through the first top, reflects from the second top, and passes through the second side, being distributed between about 2π*[1-cos(100π/180)] steradians and 4π steradians within the third solid angle between degrees.

In yet another embodiment, the second top has a recess, and in this embodiment, the second top includes a center and a rim surrounding the center; the second top is spaced apart from the substrate along the first direction so as to be along The first direction defines a height H from the edge of the second top to the top surface of the substrate; the second top extends from the center to the edge along a second direction perpendicular to the first direction, thereby defining a first radius r; the recess Including a recess depth d, which is defined as the distance from the edge to the center along the first direction; and the first ratio d/H ranges from about 0.5 to 0.8.

A number of other examples are provided below. The second side portion defines a circular area on the substrate, and the circular area has a second radius R along the second direction; and the second ratio r/R ranges between about 0.3 and about 1.0. The first top is spaced from the substrate along a first direction to define a height h relative to the top surface of the substrate; and the third ratio h/H ranges between about 0.1 and about 0.4.

The lighting structure may further include a second lens covering the first lens and disposed inside the diffuser cover. The substrate may include a mechanical mount. The mechanical base may comprise thermally conductive material and be designed as a heat sink. In another embodiment, the mechanical base includes a first portion adjacent to the LED device and a second portion away from the LED device; the first portion and the second portion are arranged along a first direction; the first portion is arranged along a direction perpendicular to the first direction The second direction has a first dimension; the second portion has a second dimension along the second direction; and the second dimension is greater than the first dimension. The lighting structure further includes a heat dissipation circuit board electrically connected with the LED device; and the heat dissipation circuit board is configured between the LED device and the substrate.

The present invention also provides another embodiment of the lighting structure. The lighting structure includes a light emitting diode (LED) device configured on a substrate; a first lens that is fixed on the substrate and covers the LED device; and is fixed on the substrate and A second lens overlays the first lens, wherein the first lens and the second lens are formed and configured to redistribute light emitted from the LED device for wide-angle illumination.

In one embodiment of the disclosed lighting structure, the first lens includes a first inner surface facing the LED device and a first outer surface facing away from the LED device; the second lens includes a second inner surface facing the LED device and a first outer surface facing away from the LED device. the second outer surface of the device; and each of the first inner surface, the first outer surface, the second inner surface, and the second outer surface is designed to have a portion selected from a hemisphere, a semiellipse, and a hemispherical circle and a surface having a top and a side with a recess. In another embodiment, the first lens and the second lens comprise a transparent material selected from the group consisting of polycarbonate (PC) and polymethyl methacrylate (PMMA). The second lens may further include diffusion particles dispersed in the transparent material to obtain a light diffusion effect. An LED device may include a plurality of LED chips configured on a substrate. The first lens may be shaped with a batwing structure. The lighting structure may further include a third lens cascaded with the first and second lenses to further redistribute the emitted light originating from the LED devices.

The invention also provides embodiments of methods of manufacturing lighting structures. The method includes attaching a light emitting diode (LED) device to a substrate; attaching a first lens to the substrate, the first lens covering the LED device; and attaching a second lens to the substrate, the second lens covered with the first lens. The method may further include forming a first lens, prior to attaching the first lens to the substrate, forming the first lens, the first lens being shaped to redistribute emitted light from the LED device. Forming the first lens may include using a technique selected from the group consisting of injection molding and extrusion molding.

The foregoing discusses components of several embodiments so that those of ordinary skill in the art may better understand the detailed description that follows. It should be understood by those skilled in the art that the present invention can be easily used as a basis to design or modify other processes and structures for achieving the same purpose and/or achieving the same advantages as the embodiments presented herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention, and that they could make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention.

Claims (22)

1. a light structures, comprising:

LED device, is positioned on substrate;

Lens, are fixed over the substrate, and are positioned at above described LED device; And

Diffused reflector, is fixed over the substrate, and is covered with described lens,

Wherein, described lens and described diffused reflector are designed and are configured to reallocate to the utilizing emitted light from described LED device, to carry out wide-angle illumination;

Described lens comprise inner surface and outer surface;

Described inner surface comprises the first sidepiece and the first top;

Described outer surface comprises the second sidepiece and the second top; And

Described second sidepiece has the bottom integrally bending cross section profile more outwardly relative to the center of described lens than top.

2. light structures according to claim 1, wherein,

Described first sidepiece, described first top, described second sidepiece and described second top are designed and are configured to be redistributed to by the light launched from described LED device in the solid angle being greater than 2 π surface of spheres.

3. light structures according to claim 2, wherein, described first sidepiece, described first top, described second sidepiece and described second top are designed and are configured so that described utilizing emitted light comprises at the running of described light structures:

First light beam, through described first top and described second top, is dispensed in the first solid angle between 0 surface of sphere and 2 π * [1-cos (π/4)] surface of sphere;

Second light beam, through described first sidepiece and described second sidepiece, is dispensed in the second solid angle between 2 π * [1-cos (π/4)] surface of sphere and 2 π * [1-cos (100 π/180)] surface of sphere; And

3rd light beam, through described first top, reflects from described second top, and through described second sidepiece, is dispensed in the 3rd solid angle of 2 π * [1-cos (100 π/180)] between surface of sphere and 4 π surface of spheres.

4. light structures according to claim 2, wherein, described second top has recess.

5. light structures according to claim 4, wherein,

Described second top comprises center and the edge around described center;

Described second top along first direction and described substrate apart, thus limits the height H from the edge at described second top to the end face of described substrate along described first direction;

Described second top crosses described edge along the second direction perpendicular to described first direction from described center, thus limits the first radius r;

Described recess comprises cup depth d, described cup depth d be defined as along described first direction from described edge to the distance at described center; And

The scope of the first ratio d/H is between 0.5 and 0.8.

6. light structures according to claim 5, wherein,

Described second side limits border circular areas over the substrate, and described border circular areas has the second radius R along described second direction; And

The scope of the second ratio r/R is between 0.3 and 1.0.

7. light structures according to claim 6, wherein,

Described first top along described first direction and described substrate apart, thus limits the height h of described first top to the end face of described substrate; And

The scope of the 3rd ratio h/H is between 0.1 and 0.4.

8. light structures according to claim 1, comprises further: the second lens, is covered with described lens, and it is inner to be configured in described diffused reflector.

9. light structures according to claim 1, wherein, described substrate comprises mechanical pedestal.

10. light structures according to claim 9, wherein, described mechanical pedestal comprises Heat Conduction Material, and is designed to radiator.

11. light structures according to claim 9, wherein,

Described mechanical pedestal comprises the contiguous Part I of described LED device and the Part II away from described LED device;

Described Part I and described Part II is configured along first direction;

Described Part I has first size along the second direction vertical with described first direction;

Described Part II has the second size along described second direction; And

Described second size is greater than described first size.

12. light structures according to claim 1, comprise: cooling circuit board further, are electrically connected with described LED device, and are configured between described LED device and described substrate.

13. 1 kinds of light structures, comprising:

LED device, is configured on substrate;

First lens, are fixed over the substrate, and are covered with described LED device; And

Second lens, are fixed over the substrate, and are covered with described first lens,

Wherein, described first lens and described second lens are shaped and configured as reallocating to the light launched from described LED device, to carry out wide-angle illumination;

The top of the outer surface of described first lens is straight section profile, the second inner surface of described second lens and the second outer surface is designed and is configured to utilizing emitted light to be reflected backward.

14. light structures according to claim 13, wherein,

Described first lens comprise the first outer surface of the first inner surface towards described LED device and described LED device dorsad;

Described second lens comprise the second outer surface of the second inner surface towards described LED device and described LED device dorsad; And

Each in first inner surface, the first outer surface, the second inner surface and the second outer surface is designed to have and is selected from by a part for hemisphere, a semielliptical part, and has the group formed with the top of recess and the surface of sidepiece.

15. light structures according to claim 13, wherein, each in described first lens and described second lens comprises transparent material, and described transparent material is selected from the group be made up of Merlon (PC) and polymethyl methacrylate (PMMA).

16. light structures according to claim 13, wherein, described second lens comprise the diffuser particles be dispersed in transparent material further, to obtain light diffusion effect.

17. light structures according to claim 13, wherein, described LED device comprises multiple LED chip be configured over the substrate.

18. light structures according to claim 13, wherein, described first lens are shaped as has batwing structure.

19. light structures according to claim 13, comprise further: the 3rd lens, with described first lens and described second lens stacked, to reallocate to the light launched from described LED device further.

20. 1 kinds of methods manufacturing light structures, comprising:

LED device is attached to substrate;

First lens are attached to described substrate, make described first lens be covered with described LED device; And

Second lens are attached to described substrate, make described second lens be covered with described first lens;

The top of the outer surface of described first lens is straight section profile, the second inner surface of described second lens and the second outer surface is designed and is configured to utilizing emitted light to be reflected backward.

21. methods according to claim 20, comprise further: before described first lens are attached to described substrate, form the first lens, described first lens are shaped as: reallocate to the utilizing emitted light from described LED device, to form wide-angle illumination.

22. methods according to claim 21, wherein, described formation first lens comprise: use the technology being selected from the group be made up of injection molding and extrusion molding.